Fuse Box Visual Status Indicator Using LED Intermediary
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Solution Overview
Problem
Existing fuse box systems lack a reliable visual indication of fuse failure, especially when loads are inactive or draw less current, and they cannot monitor load current for diagnosing circuit problems, leading to safety issues and difficulties in diagnosing failures in geographically diverse systems.
Innovation Solution
A fuse box system incorporating a fuse status sensor, reference voltage generator, comparator, and fuse status indicator that uses LEDs to provide visual feedback on fuse status, allowing remote interrogation and permitting reuse of fuses, operation over a wide range of voltages, and programmable fuse trip points, with the ability to retrofit existing panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional fuses are used without visual indicators, then the system structure remains simple and cost-effective, but it becomes impossible to visually detect fuse failure without removing and testing each fuse individually
Solution Approach 1:
The patent introduces an intermediary LED indicator system that mediates between the fuse status and the human observer. The LED circuit acts as a mediator that converts the electrical state of the fuse (connected/disconnected) into visible light signals, allowing status detection without direct physical inspection of the fuse itself.
Solution Approach 2:
The patent replaces the mechanical/physical inspection method (removing fuses and using continuity testers) with an optical detection system. The LED-based visual indicator system substitutes the need for manual mechanical testing, enabling remote and immediate status assessment.
2Reliability
If LED indicators are added to show fuse status, then visual detection of blown fuses becomes possible, but the system cannot detect failures when loads are inactive or draw minimal current
Solution Approach 1:
The patent implements preliminary action by continuously monitoring fuse status through the LED indicator system before actual fuse failure occurs. The system proactively detects open circuits and potential failures by monitoring current flow characteristics, enabling early warning and preventive maintenance rather than reactive response.
Solution Approach 2:
The patent employs feedback mechanisms where the LED indicator system continuously monitors and provides visual feedback on fuse and load status. The system adjusts its monitoring based on detected conditions, providing different visual signals for normal operation, open circuits, and potential failures, enabling adaptive response to varying operational states.
3Loss of time
If fuses must be removed and tested with continuity testers to determine failure, then the detection method remains simple, but diagnostic time increases significantly in systems with many geographically diverse fuse panels
Solution Approach 1:
The patent implements self-service by enabling the fuse box system to automatically monitor and report its own status through LED indicators. The system performs self-diagnostics without requiring external testing equipment or manual intervention, continuously assessing fuse integrity and load status and providing immediate visual feedback on its operational state.
Solution Approach 2:
The patent utilizes color changes in LED indicators to convey different fuse and load statuses. Different LED colors or illumination patterns indicate normal operation, open circuits, potential failures, or other diagnostic conditions, enabling rapid visual assessment of system health without technical testing equipment.
4Ease of repair
If spare fuses are not readily available in field situations, then system portability and simplicity are maintained, but repair capability and system availability are compromised
Solution Approach 1:
The patent applies preliminary action by continuously monitoring fuse status and providing early warning of potential failures before actual blowout occurs. This allows maintenance personnel to prepare replacement fuses in advance or schedule maintenance during planned downtime, rather than experiencing unexpected failures that require immediate field repairs.
Solution Approach 2:
The patent uses feedback through LED indicators to provide real-time information on fuse and load status, enabling informed decision-making about maintenance needs. The system feedback mechanism allows users to assess whether fuses need replacement and plan accordingly, improving field repair efficiency and system availability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides reliable visual and remote monitoring of fuse status, enabling efficient diagnosis and maintenance, ensuring safety and reducing downtime by allowing fuses to be reused and operating effectively across various voltage ranges, while preventing incorrect replacement.
Implementation Method 1
The fuse has one of several different configurations, depending on whether the fuse is used in a system that is used in a polarized or non-polarized system. In each scenario, the fuse includes a number of diodes, including a plurality if light emitting diode (LED) that will be illuminated when the fuse is working
Data Source
AI summary
A fuse box system and method providing for visual and/or remote sensing of interrupted fusing elements is disclosed. The system incorporates LEDs and/or remote sensing apparatus to permit indication of a “blown” fuse and/or circuit protection breaker. This system may be configured for both polarized and/or non-polarized applications and generally provides for indicator illumination when a fuse/breaker is blown. Some preferred embodiments may incorporate current sourcing technologies to permit operation of the system over wide range of system voltages, as well as provisions for wired and/or RF/wireless interrogation of the fuse/breaker status. Alternate embodiments including systems/methods to permit remote sensing of fuse status and/or circuit current monitoring, and may be retrofit within existing fuse/breaker panel systems in some configurations.